• Proceedings of the Korean Society of Precision Engineering Conference
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• 2005.06a
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• pp.133-138
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• 2005

Automotive pulleys play a key role in driving the cooling pump, oil pump, air-conditioner and so on by using an engine power. Researches on design processes and technologies of the pulleys can be found in many literatures. On the other hand, the areas related to manufacturing processes of the pulleys have been treated negligently. Vast data extracted from various information systems are transformed, integrated, and summarized to become a special database for helping users make a decision. The database, namely the data warehouse has been popularly used in the marketing and customer management of enterprises and recently applied to improve the design and manufacturing processes. In this study the manufacturing process of pulleys were analyzed through the intensive investigation of shop-floors and the interviews with workers and managers. The defects generated during a manufacturing process were categorized in a few types and the causes of defects examined for extracting the dominant parameters in the setup process for producing pulleys. As the first step to construct the data warehouse for the manufacturing processes of pulleys, authors proposed its architecture focused on the reduction of defect rate during the setup process.

• Korean Journal of Materials Research
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• v.21 no.12
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• pp.685-689
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• 2011

The goal of this investigation was to produce a zirconia-family black ceramics that has enhanced functionality and reliability. Color zirconia ceramics have been produced by adding pigments. Pigments cause structural defects within zirconia and result in a drop in physical properties. Using environmentally friendly rice husk, we produced a black zirconia that is free of structural defects. In optimal firing conditions for black zirconia the calcining temperatures of the molding product are changed from $400^{\circ}C$ to $1200^{\circ}C$, and the firing temperatures are changed from $1400^{\circ}C$ to $1600^{\circ}C$. Color of testing the specimens was analyzed using Ultraviolet (UV) spectroscopy. Scanning Electron Microscope (SEM), EDAX (EDX), and Fourier transform infrared spectroscopy (FT-IR) analyses were carried out in order to examine impregnation properties and crystal phases. Universial Test Machine (UTM) was used to measure the flexual strength as well as the compressive strength. From experimental results, it was found that in optimal firing conditions the sample was calcined from $1000^{\circ}C$ to $1500^{\circ}C$. Commission internationalde I'Edairage (CIE) values of manufactured black zirconia color were $L^*$ = 29.73, $a^*$ = 0.23, $b^*$ = -2.68. The bending strength was 918 MPa and the compressive strength was 2676 MPa. These strength values are similar to typical strength values of zirconia, which confirms that carbon impregnation did not influence physical properties.

• Journal of the Korean Society for Aeronautical & Space Sciences
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• v.45 no.1
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• pp.71-78
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• 2017

The electrical power system of Korean Utility Helicopter(KUH) is designed as a dual control system to enhance the system safety of aircraft and each system is installed separately at left and right of the aircraft. The system is composed of 2 AC generators, 1 APU generator, 2 Transformer Rectifier Units(TRU), AC/DC Electrical Master Box(AC/DC EMB). The AC/DC EMB, consists of 2 AC EMB and 2 DC EMB, is essential equipment which supply and distribute electric power to the aviation electronics and electrical equipment of KUH. There were defects caused by internal short circuit in AC EMB during the first production phase of the KUH. This paper describes the analysis of the defects, troubleshooting process, root cause, and the solution by design change.

• Journal of Korean Society of Steel Construction
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• v.23 no.2
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• pp.159-167
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• 2011

Steel structure construction is currently increasing on account of the many merits of steel structures. Due to numerous environmental factors, many cracks and extensive corrosion occur in steel structures, which cause the deterioration of the performance and life cycle of such structures. Maintenance of steel structures is thus strongly demanded, for safety control. The inspection methods that are currently being used, however, are very limited and can detect only local defects in steel structures. They also take much time to use and incur high maintenance costs. Moreover, such methods cannot be applied to huge steel structures, which men find unapproachable. They also require much time due to the need for periodic checks, and may lead to cost loss. Therefore, the development of a monitoring system that can detect defects in whole structures and can reduce the repair and strengthening costs at an early stage is very much needed. In this study, the generation and propagation of cracks were monitored via the electric-potential-drop method (EPDM).

• Transactions of the Korean Society of Mechanical Engineers A
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• v.38 no.6
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• pp.637-647
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• 2014

In pressurized water reactors, the upper head of the reactor pressure vessel (RPV) contains numerous control rod drive mechanism (CRDM) nozzles. These nozzles are fabricated by welding after being inserted into the RPV head with a room temperature shrink fit. The tensile residual stresses caused by this welding are a major factor in primary water stress corrosion cracking (PWSCC). Over the last 15 years, the incidences of cracking in alloy 600 CRDM nozzles have increased significantly. These cracks are caused by PWSCC and have been shown to be driven by the welding residual stresses and operational stresses in the weld region. Various measures are being sought to overcome these problems. The defects resulting from the welding process are often the cause of PWSCC acceleration. Therefore, any weld defects found in the RPV manufacturing process are immediately repaired by repair welding. Detailed finite-element simulations for the Korea Nuclear Reactor Pressure Vessel were conducted in order to predict the magnitudes of the repair weld residual stresses in the tube materials.

• Transactions of Materials Processing
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• v.25 no.1
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• pp.12-20
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• 2016

Press machines and dies are commonly used for 3D curved sheet forming. Using conventional die forming can cause economic problems since various modifications of the die shape are required depending on the product shape. Various types of flexible forming such as multi-point dieless forming (MDF), flexible incremental roll forming have been developed to improve the needed process flexibility. Although MDF can reduce the production cost using reconfigurable dies, it still has significant material loss. Drawbacks such as wrinkling, dimpling, and forming errors can also occur despite continuous investigations to mitigate these defects. A novel sheet forming process for 3D curved surfaces, a flexibly-reconfigurable roll forming (FRRF), has been recently proposed to overcome the economic and technical limitations of current practice. FRRF has no limitation on blank size in the longitudinal direction, and also minimizes or eliminates forming defects such as wrinkling and dimpling. Feasibility studies of FRRF have been conducted using FE simulations for multi-curved shapes and various sheet thicknesses. Therefore, the fabrication of a FRRF apparatus is required for any follow-up studies. In the current study, experiments with reconfigurable rollers were conducted using a simple design pre-FRRF apparatus prior to fabricating the full size FRRF apparatus. There are three candidates for the reconfigurable roller: a bar-type shaft, a flexible shaft, a ground flexible shaft. Among these candidates, the suitable reconfigurable roller for FRRF is determined through various forming tests.

• KIPS Transactions on Software and Data Engineering
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• v.11 no.2
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• pp.67-80
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• 2022

Recently, many laundry home appliances have been released with Internet of Things (IoT) functions, but there are few quality evaluation tests for IoT functions. In particular, since IoT test items are not prepared for laundry home appliances applied with IoT functions, it is difficult to find the cause even if defects occur, and test institutions are limited in selecting test items related to IoT and conducting proper performance tests. In this paper, we design a test item framework that separates IoT test items into commonality and variability to identify product defects and causes for laundry home appliances with IoT features among products in the field of home appliances. Through the proposed research, manufacturers and test institutions can test the proper performance of laundry products with IoT functions, which can improve the completeness of the products and ensure reliability.

• KIPS Transactions on Software and Data Engineering
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• v.10 no.6
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• pp.211-222
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• 2021

Recently, frozen and refrigerated appliances on the market are being released with additional IoT functions, but there are few tests on IoT functions. In particular, the existing test system does not have IoT test items for IoT-based frozen and refrigerated appliances, making it difficult for companies to find the cause even if defects occur, and test institutions are also restricted from selecting IoT-related test items and conducting correct performance tests. In this paper, we design a test item framework that can identify product defects and identify causes in the performance test process of frozen and refrigerated products with IoT functions among products in the home appliance field, and propose test methods and management measures using them. Through the proposed research, manufacturers and testing institutions can test the correct performance of IoT-based frozen and refrigerated products, thereby enhancing the completeness and securing reliability of the products.

• Journal of the Korean Society of Safety
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• v.37 no.4
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• pp.20-27
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• 2022

This article aims to develop an algorithm that detects fire pump defects by analyzing the current signals of an induction motor, which are triggered by changes in the flow rate and pressure of multistage volute pumps that are used for fire services. The operational status of the pumps was categorized into three: first, normal operation; second, a defect that is caused by a change in the current value; and third, a defect occasioned by a change in current, pressure, and flow rate. When a fire pump was in normal operation, the motor's operating current was measured between 5.06 A and 6.9 A, the flow rate was estimated at 0-0.27 m³/min, and the pressure ranged from 0 to 0.47 MPa. In the event that a defect was caused by an abnormal current value in the motor, it was attributed to the pump's adherence. Furthermore, if there was no source of water, the defect was considered to have been induced by phase-loss operation, no-load operation, or run-stop operation, with the current value of each scenario being measured at > 52.8 A, < 4.13 A, > 45.15 A, and < 3.8 A, respectively, placing its overall range between 0 and 50 A. The sources of defects were detected based on an analysis of the flow rate, pressure, and current, which represent the following causes: air inflow into the casing, inadequate suction of water, and reverse-phase operation, respectively. Each cause entailed the following values: when air seeped into the casing, the pressure was measured at 0.24 MPa irrespective of changes in the flow rate; when there was inadequate suction of water, the pressure was recorded between 0 and 0.05 MPa despite changes in the flow rate; and when the power line's reverse-phase loss was the cause of the defect, the pressure was measured at 0.33 MPa for a flow rate of 0 L/min, and a higher flow rate decreased the pressure to nearly 0 MPa. The results of this study will enable engineers to develop a pump defect detection algorithm that is based on an analysis of current, and this algorithm will facilitate the execution of a program that will control a fire pump defect detection system.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.17 no.7
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• pp.434-441
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• 2016

Friction Stir Welding (FSW) is a solid-state joining process involving the frictional heat between the materials and tools. The amount of heat conducted into the workpiece determines the quality of the welded zone. Excessive heat input is the cause of oxides and porosity defects, and insufficient heat input can cause problems, such as tunnel defects. Therefore, analyzing the temperature history and distribution at the center of the Friction Stir Welded zone is very important. In this study, the temperature distribution of the friction stir welding region of an AZ61 magnesium alloy was investigated. To achieve this goal, the temperature and metal flow was predicted using the finite element method. In FE analysis, the welding tool was simplified and the friction condition was optimized. Moreover, the temperature measuring test at the center of the welding region was performed to verify the FE results. In this study, the tool rotation speed was a more dominant factor than the welding speed. In addition, the predicted temperature at the center of the welding region showed good agreement with the measurement results within the error range of 5.4% - 7.7%.